I just put a set of BD boots on my 2002. Drove it to work the next day round trip 100 miles and it used 1/2 a tank of fuel. Also when I accelerate I hear a loud high pitched whistle that sounds like a party horn and is not the turbo. So today I built a boost leak tester and pressurized the system to 10psi. Every one of the new boots leaks so bad the system wont the 10psi for more than 15 seconds or so. I spent 3 hours adjusting and tightening the spring clamps and still cannot get it to hold pressure. All the surfaces have been cleaned with brake cleaner wiped down dry and still no success.
Any ideas or recomendations on another brand of boots or a way to get these to seal would be helpful? I would hate to have to spend another 200 to have the same issue.

I just put a set of BD boots on my 2002. Drove it to work the next day round trip 100 miles and it used 1/2 a tank of fuel. Also when I accelerate I hear a loud high pitched whistle that sounds like a party horn and is not the turbo. So today I built a boost leak tester and pressurized the system to 10psi. Every one of the new boots leaks so bad the system wont the 10psi for more than 15 seconds or so. I spent 3 hours adjusting and tightening the spring clamps and still cannot get it to hold pressure. All the surfaces have been cleaned with brake cleaner wiped down dry and still no success.
Any ideas or recomendations on another brand of boots or a way to get these to seal would be helpful? I would hate to have to spend another 200 to have the same issue.

Thanks

AHAHAHAHAHA this made my day. Id try using a heat gun to try softening them to get it to take shape of the pipes if not try calling BD and see what they say.

I did the plenum inserts and they work well. infact thats the only place it doesnt leak. Both inercooler tubes at the top and bottom leak. I called the place I ordered them from and they said "crank down on the clamps". Did that and they still leak. They went on almost to easy, seems you would want a tighter fitting and thicker boot to prevent them from deforming when you add clamp pressure. Not too pleased with a 10psi leak after spending coin like that.

Yea the boots should fight you a little when put the pipe into them i messed around with mine for 10min on the top with the clamp off completely the bottom going to the inter cooler well lets not go there lol.

Fixed it! I removed the new boots and cleaned them reinstalled and pressure tested again. Same thing still leaked. So just for kicks I removed the new spring loaded clamps that came with the kit and installed the old stock clamps, pressure tested with slight leaks, snugged them down one at a time till they stopped. Runs like a champ!

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